Flow control valve and cooling system

ABSTRACT

Provided is a flow control valve and a cooling system, with which a pressure loss can be reduced. A rotor 12 includes a first guide portion 43 on the outer circumferential side of an extending portion 42 fixed to a drive shaft 13 and protruding into a space inside the rotor 12. The first guide portion 43 has a radial outer shape which increases from an x-axis positive direction side toward an x-axis negative direction side.

TECHNICAL FIELD

The invention relates to flow control valves and cooling systems.

BACKGROUND ART

The flow control valves generally known are those with a rotatable valve element (Patent Literature 1, for example).

CITATION LIST Patent Literature

PTL 1: Japanese Unexamined Patent Application Publication (Kokai) No. 2004-76647

SUMMARY OF INVENTION Technical Problem

The flow control valves in relevant art cause a large fluid pressure loss due to a valve-element supporting structure which is protruding inside a valve element.

An object of the invention is to provide a flow control valve and a cooling system, with which a pressure loss can be reduced.

Solution to Problem

According to a flow control valve of one embodiment of the invention, a valve element includes a first guide portion on an outer circumferential side of an extending portion which is fixed to a drive shaft and protruding into a space inside the valve element. The first guide portion has a radial outer shape which increases from one axial side toward the other axial side.

The one embodiment of the invention thus can reduce the pressure loss.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic view of a cooling system 1 according to an Embodiment 1.

FIG. 2 is a perspective view of an MCV 9 according to the Embodiment 1.

FIG. 3 is an exploded perspective view of the MCV 9 according to the Embodiment 1.

FIG. 4 is a plan view of the MCV 9 according to the Embodiment 1.

FIG. 5 is a perspective view of a section taken along line S5-S5 of FIG. 4 as viewed from the direction indicated by the arrow.

FIG. 6 is a sectional view taken along line S5-S5 of FIG. 4 as viewed from the direction indicated by the arrow.

FIG. 7 is a sectional view taken along line S7-S7 of FIG. 4 as viewed from the direction indicated by the arrow.

FIG. 8 is a perspective view (showing a housing only) of a section taken along a line S8-S8 of FIG. 4 as viewed from the direction indicated by the arrow.

FIG. 9 is a perspective view of a rotor 12 according to the Embodiment 1.

FIG. 10 is a perspective view of the rotor 12 of FIG. 9 in a position turned at 180 degrees.

FIG. 11 is a sectional view taken along line S5-S5 of FIG. 4 according to an Embodiment 2 as viewed from the direction indicated by the arrow.

FIG. 12 is a sectional view taken along line S5-S5 of FIG. 4 according to an Embodiment 3 as viewed from the direction indicated by the arrow.

FIG. 13 is a schematic view of a cooling system 100 according to an Embodiment 4.

DESCRIPTION OF EMBODIMENTS Embodiment 1

FIG. 1 is a schematic view of a cooling system 1 according to an Embodiment 1.

The cooling system 1 of the Embodiment 1 includes a circuit 7 configured to pass coolant (fluid), which has cooled an engine 2 functioning as a heat source, through a plurality of heat exchangers (radiator 3, transmission fluid warmer 4, heater 5) and then deliver the coolant back to the engine 2 via a water pump 6. The engine 2 is, for example, a gasoline engine installed in a vehicle. The radiator 3 cools the coolant through heat exchange between the coolant and relative wind. The transmission fluid warmer 4 cools the coolant through heat exchange between the coolant and a transmission fluid. The transmission fluid warmer 4 raises the temperature of the transmission fluid when the engine 2 is cold, and also functions as a fluid cooler for cooling the transmission fluid after the warm-up of the engine 2 is finished. The heater 5 cools the coolant through heat exchange between the coolant and the air blown into a vehicle interior while the vehicle interior is being heated. The water pump 6 is rotationally driven by a driving force of the engine 2 and feeds the engine 2 with the coolant from the radiator 3, the transmission fluid warmer 4, and the heater 5. The circuit 7 includes a normally-open water passage 7 a for constantly circulating the coolant, bypassing the heat exchangers 3, 4 and 5. A water temperature sensor 8 for detecting coolant temperature (water temperature) is placed in the normally-open water passage 7 a. A mechanical control valve (hereinafter, referred to as MCV) 9 is a flow rate control valve configured to adjust a flow rate of the coolant which is fed from the engine 2 to the heat exchangers 3, 4 and 5. The MCV 9 will be discussed later in details. An engine control unit 101 is configured to control a valve rotation angle of the MCV 9 in accordance with the water temperature detected by the water temperature sensor 8, information (engine negative pressure, throttle opening degree, etc.) of the engine 2, and the like.

A configuration of the MCV 9 will be now explained.

FIG. 2 is a perspective view of the MCV 9 according to the Embodiment 1. FIG. 3 is an exploded perspective view of the MCV 9. FIG. 4 is a plan view of the MCV 9. FIG. 5 is a perspective view of a section taken along line S5-S5 of FIG. 4 as viewed from the direction indicated by the arrow. FIG. 6 is a sectional view taken along line S5-S5 of FIG. 4 as viewed from the direction indicated by the arrow. FIG. 7 is a sectional view taken along line S7-S7 of FIG. 4 as viewed from the direction indicated by the arrow. FIG. 8 is a perspective view (showing a housing only) of a section taken along a line S8-S8 of FIG. 4 as viewed from the direction indicated by the arrow. FIG. 9 is a perspective view of a rotor 12 according to the Embodiment 1. FIG. 10 is a perspective view of the rotor 12 of FIG. 9 in a position turned at 180 degrees.

The MCV 9 includes the housing 10, a drive mechanism 11, the rotor (valve element) 12, and a drive shaft 13. Hereinafter, an x-axis represents a direction along a rotational axis of the drive shaft 13. A direction from the drive mechanism 11 toward the rotor 12 along the x-axis is referred to as an x-axis positive direction, and an opposite direction as an x-axis negative direction. A radiation direction of the x-axis is referred to as a radial direction, and a direction around the x-axis as a circumferential direction.

First, a configuration of the housing 10 will be explained.

The housing 10 is formed by casting out of an aluminum alloy material, for example. The housing 10 includes a base portion 14, a circumferential wall 15, a main communicating port 16, a plurality of sub-communicating ports 17, and a bearing portion 18. The base portion 14 has a substantially disk-like shape and is perpendicular to the x-axis direction. The drive shaft 13 extends in the x-axis direction through a center of the base portion 14. A stopper 14 a is provided in an x-axis positive direction-side surface of the base portion 14. The stopper 14 a is protruding in the x-axis positive direction. The circumferential wall 15 has a substantially cylindrical shape and extends from an outer circumference of the base portion 14 in the x-axis positive direction. The circumferential wall 15 is tapered in such a way that an inner diameter increases from the x-axis negative direction side toward the x-axis positive direction side. A valve element housing portion 19 is provided on an inner circumferential side of the circumferential wall 15. The valve element housing portion 19 is a substantially columnar space. The rotor 12 is accommodated in the valve element housing portion 19. The main communicating port 16 is a circular opening portion which is formed at an x-axis positive direction end of the circumferential wall 15 (x-axis positive direction end of the housing 10). The main communicating port 16 is in communication with the valve element housing portion 19. A water passage, which extends from the engine 2, and the valve element housing portion 19 are connected together through the main communicating port 16. The plurality of sub-communicating ports 17 are circular opening portions formed in the circumferential wall 15 and communicate with the valve element housing portion 19. The plurality of sub-communicating ports 17 comprise a first sub-communicating port 17 a, a second sub-communicating port 17 b, and a third sub-communicating port 17 c. The first sub-communicating port 17 a has the smallest opening area. The third sub-communicating port 17 c has the largest opening area. The second sub-communicating port 17 b is located further on the x-axis negative direction side than the first sub-communicating port 17 a. The third sub-communicating port 17 c is located further on the x-axis positive direction side than the first sub-communicating port 17 a. As viewed from the x-axis negative direction side, the second sub-communicating port 17 b and the third sub-communicating port 17 c are located away from the first sub-communicating port 17 a clockwise by 90 and 180 degrees, respectively.

Outlets (conduits) 20 a, 20 b and 20 c functioning as pipe joints are fixed to radial outer sides of the sub-communicating ports 17 a, 17 b and 17 c. The first outlet 20 a connects the first sub-communicating port 17 a and a water passage extending toward the heater 5. The second outlet 20 b connects the second sub-communicating port 17 b and a water passage extending toward the transmission fluid warmer 4. The third outlet 20 c connects the third sub-communicating port 17 c and a water passage extending toward the radiator 3. Outer circumferences of the first and second outlets 20 a and 20 b and respective inner circumferences of the first and second sub-communicating ports 17 a and 17 b are sealed with O-rings 21 a and 21 b at radial inner ends of the first and second outlets 20 a and 20 b. A fourth sub-communicating port 17 d is formed in the housing 10. The fourth sub-communicating port 17 d is in constant communication with the main communicating port 16, regardless of a rotation angle of the rotor 12. A fourth outlet 20 d functioning as a pipe joint is fixed to a radial outer side of the fourth sub-communicating port 17 d. The fourth outlet 20 d connects the fourth sub-communicating port 17 d and the normally-open water passage 7 a. A fifth sub-communicating port 17 e is also formed in the housing 10. The fifth sub-communicating port 17 e is in communication with the fourth sub-communicating port 17 d. A water passage, not shown, is formed in the third outlet 20 c. This water passage connects the fifth sub-communicating port 17 e and the first sub-communicating port 17 a. A thermostat 22 is accommodated in this water passage. The thermostat 22 has a fail-safe function which opens the water passage when the water temperature is excessively increased (to 100 or higher degrees Celsius, for example), and thus accelerates the reduction of the water temperature. The x-axis positive direction end of the housing 10 has three attaching holes 23 into which bolls are inserted when the MCV 9 is bolted to the engine 2.

The bearing portion 18 supports the drive shaft 13 in such a way that the drive shaft 13 is rotatable relative to the housing 10. The bearing portion 18 is formed into a substantially cylindrical shape extending along the x-axis direction. The bearing portion 18 has an x-axis negative direction end which is protruding further toward the x-axis negative direction side than an x-axis negative direction end of the base portion 14. The bearing portion 18 further has an x-axis positive direction end which is protruding further toward the x-axis positive direction side than an x positive direction end of the base portion 14. The x-axis positive direction end of the bearing portion 18 is located further on the x-axis negative direction side than the x-axis positive direction end of the second sub-communicating port 17 b. A through-hole 18 a is formed in a center of the bearing portion 18. The drive shaft 13 extends through the through-hole 18 a. Inside the through-hole 18 a, the bearing portion 18 includes a radial thrust bearing (first radial bearing) 24, a dust seal 25, a liquid-tight seal 26, and a thrust bearing 27. The radial thrust bearing 24 is located at the x-axis negative direction end of the bearing portion 18 and receives radial and x-axis forces from the drive shaft 13. The dust seal 25 is located between the radial thrust bearing 24 and the liquid-tight seal 26 in the x-axis direction and prevents the coolant, which has flown into the bearing portion 18, from entering the drive mechanism 11. The liquid-tight seal 26 is located between the dust seal 25 and the thrust bearing 27 in the x-axis direction and prevents the coolant from flowing out of the valve element housing portion 19. The thrust bearing 27 is located at the x-axis positive direction end of the bearing portion 18 and receives the x-axis force from the drive shaft 13. The housing 10 has a relief hole 28 connecting the through-hole 18 a and a space on an x-axis negative direction side of the base portion 14. The relief hole 28 is located on the x-axis negative direction side of the stopper 14 a. The relief hole 28 functions to discharge the coolant and air, which have flown into the bearing portion 18 (through-hole 18 a), to the outside of the housing 10. The relief hole 28 is inclined with respect to the x-axis. The relief hole 28 extends from the through-hole 18 a in the x-axis negative direction and a radially outward direction to open in the x-axis negative direction side of the base portion 14. The relief hole 28 extends from the through-hole 18 a in the x-axis negative direction and a radially outward direction to open in the x-axis negative direction side of the base portion 14.

A configuration of the drive mechanism 11 will be explained below.

The drive mechanism 11 is located on the x-axis negative direction side of the base portion 14 and rotationally drives the drive shaft 13. The drive mechanism 11 includes an electric motor 29, a motor worm 30, an intermediate gear 31, an intermediate worm 32, and a rotor gear 33. The electric motor 29 is controlled by the engine control unit 101. The electric motor 29 is accommodated in the housing 10 with an output shaft 29 a oriented in the x-axis negative direction. The motor worm 30 rotates integrally with the output shaft 29 a. The intermediate gear 31 is meshingly engaged with the motor worm 30. The intermediate worm 32 is formed integrally with the intermediate gear 31. An intermediate shaft 34 extends through the center of the intermediate gear 31 and the intermediate worm 32. The intermediate shaft 34 has an axis perpendicular to the x-axis. The intermediate shaft 34 is supported by two shaft support portions 35 a and 35 b so as to be rotatable about the axis of the intermediate shaft 34. The shaft support portions 35 a and 35 b extend from the base portion 14 in the x-axis negative direction. The rotor gear 33 is fixed to an x-axis negative direction end of the drive shaft 13 and rotates integrally with the drive shaft 13. A magnet 36 is attached to the x-axis negative direction end of the drive shaft 13. The magnet 36 is not shown in the attached drawings except FIG. 3. The motor worm 30, the intermediate gear 31, the intermediate worm 32, and the rotor gear 33 are accommodated in a gear housing 37. The gear housing 37 includes a magnetoresistive (MR) sensor, not shown. The MR sensor detects a rotation angle of the drive shaft 13, namely, a rotation angle of the rotor 12, on the basis of a change caused in a magnetic field by the rotation of the drive shaft 13. The rotation angle detected by the MR sensor is transmitted to the engine control unit 101.

A configuration of the rotor 12 will be now explained.

The rotor 12 is accommodated in the valve element housing portion 19. The rotor 12 is made of, for example, a synthetic resin material. The rotor 12 includes a bottom portion 38, an outer circumferential portion 39, a main opening portion 40, a plurality of sub-opening portions 41, and an extending portion 42. The bottom portion 38 is located on the x-axis negative direction side of the rotor 12 and perpendicular to the x-axis direction. The bottom portion 38 has a donut-like shape, a little over 180-degree-angle segment of which is cut away with only an outer circumferential portion of the segment left, as viewed from the x-axis negative direction side. The outer circumferential portion 39 has a substantially cylindrical shape extending from an outer circumference of the bottom portion 38 in the x-axis positive direction. The outer circumferential portion 39 is tapered in such a way that an inner diameter increases from the x-axis negative direction side toward the x-axis positive direction side. The outer circumferential portion 39 includes a flange portion 39 a extending from the x-axis positive direction end of the outer circumferential portion 39 in the radially outward direction. A slide bearing (second radial bearing) 44 is provided near the x-axis positive direction end of the circumferential wall 15 and further on the x-axis negative direction side than the flange portion 39 a. The slide bearing 44 supports the rotor 12 in such a way that the rotor 12 is rotatable relative to the housing 10. The slide bearing 44 receives the radial force from the rotor 12. The main opening portion 40 is a circular opening portion which is formed at the x-axis positive direction end of the outer circumferential portion 39 (x-axis positive direction end of the rotor 12). The main opening portion 40 is in communication with the main communicating port 16. The plurality of sub-opening portions 41 are opening portions formed in the outer circumferential portion 39. The plurality of sub-opening portions 41 comes into communication with the respective plurality of sub-communicating ports 17 a, 17 b and 17 c when the rotor 12 is positioned within a predetermined rotation angle range. The plurality of opening portions 41 comprise a first sub-opening portion 41 a, a second sub-opening portion 41 b, and a third sub-opening portion 41 c. The first sub-opening portion 41 a corresponds to the first sub-communicating port 17 a. The second sub-opening portion 41 b corresponds to the second sub-communicating port 17 b. The third sub-opening portion 41 c corresponds to the third sub-communicating port 17 c. The second sub-opening portion 41 b is located further on the x-axis negative direction side than the first sub-opening portion 41 a. The third sub-opening portion 41 c is located further on the x-axis positive direction side than the first sub-opening portion 41 a. The second sub-opening portion 41 b is formed into an elongate hole extending in a circumferential direction. The first and third sub-opening portions 41 a and 41 c each have a circular shape. The second sub-opening portion 41 b is shorter in x-axis length than the first sub-opening portion 41 a. The third sub-opening portion 41 c is larger in opening area than the second sub-opening portion 41 b. The first sub-opening portion 41 a includes two opening portions 41 a 1 and 41 a 2. The opening portion 41 a 1 is for summer use, whereas the opening portion 41 a 2 is for winter use. The third sub-opening portion 41 c also includes two opening portions 41 c 1 and 41 c 2. The opening portion 41 c 1 is for summer use, whereas the opening portion 41 c 2 is for winter use. The first sub-opening portion 41 a (41 a 1, 41 a 2) overlaps with a first guide portion 43 in the x-axis direction.

The extending portion 42 extends from the outer circumference of the bottom portion 38 in the x-axis positive direction to be joined to the x-axis positive direction end of the drive shaft 13. The extending portion 42 includes a tip portion 42 a, a cylindrical portion (tubular portion) 42 b, and a second guide portion 42 c. The tip portion 42 a is provided at an x-axis positive direction end of the extending portion 42. The tip portion 42 a is located on the x-axis positive direction side of the bearing portion 18 of the housing 10 and fixed to the drive shaft 13. A metallic insert 42 d for reinforcement is embedded in a center of the tip portion 42 a and in a joined portion between the tip portion 42 a and the drive shaft 13. The rotor 12 is insert-molded with the insert 42 d used as an insert. An x-axis positive direction side of the tip portion 42 a overlaps with the first sub-communicating port 17 a of the housing 10 in the x-axis direction. An x-axis positive direction end of the tip portion 42 a is located further on the x-axis negative direction side than the x-axis positive direction end of the first sub-communicating port 17 a, and yet further on the x-axis positive direction side than the x-axis negative direction side of the first sub-communicating port 17 a. The tip portion 42 a has an outer circumferential surface which is provided with the first guide portion 43. The first guide portion 43 is tapered in such a way that a radial dimension increases from the x-axis positive direction side toward the x-axis negative direction side. The cylindrical portion 42 b is formed into a cylindrical shape which extends from the first guide portion 43 in the x-axis negative direction. The cylindrical portion 42 b has an inner diameter which is larger than an outer diameter of the bearing portion 18. The cylindrical portion 42 b overlaps with the bearing portion 18 in the x-axis direction. An x-axial end of the cylindrical portion 42 b is connected to the second guide portion 42 c in an area where the cut-away segment of the bottom portion 38 is located in the circumferential direction and connected to the bottom portion 38 in an area where the other segment is located. The second guide portion 42 c is provided in the cut-away segment of the bottom portion 38 in the circumferential direction and thus connects the cylindrical portion 42 b and the outer circumference of the bottom portion 38. The second guide portion 42 c is connected to an opening rim on an x-axis negative direction side of the second sub-opening portion 41 b. The second guide portion 42 c is tapered in such a way that a radial outer shape increases from the x-axis positive direction side toward the x-axis negative direction side. The bottom portion 38 includes two connecting portions 38 a and 38 b which are connected to the second guide portion 42 c. The connecting portions 38 a and 38 b extend along the x-axis direction. Each of the connecting portions 38 a and 38 b is circumferentially engaged with the stopper 14 a of the base portion 14 when the rotor 12 is positioned at the corresponding predetermined rotation angle. The rotor 12 rotates clockwise as viewed from the x-axis negative direction side from a position where the connecting portion 38 a is in contact with the stopper 14 a of the base portion 14. The rotor 12 is rotatable within a range of an angle of a little less than 180 degrees upon till the connecting portion 38 b comes into contact with the stopper 14 a.

Seal portions 45, 46 and 47 provided to the sub-communicating ports 17 a, 17 b and 17 c will be explained below.

The first seal portion 45 is provided to the first sub-communicating port 17 a. The first seal portion 45 prevents the coolant from leaking from the first sub-communicating port 17 a into a radial clearance between the circumferential wall 15 and the outer circumferential portion 39 while the first sub-communicating port 17 a and the first sub-opening portion 41 a are in communication. The first seal portion 45 includes a rotor seal 45 a, an O-ring 45 b, and a coil spring 45 c. The rotor seal 45 a has a cylindrical shape and is inserted in the first sub-communicating port 17 a. The rotor seal 45 a has a radial inner end which is in contact with the outer circumferential portion 39. The O-ring 45 b seals a gap between an inner circumferential surface of the first sub-communicating port 17 a and an outer circumferential surface of the rotor seal 45 a. The coil spring 45 c is radially interposed between the rotor seal 45 a and the first outlet 20 a in a compressed position to bias the rotor seal 45 a in a radially inward direction. The second seal portion 46 is provided to the second sub-communicating port 17 b. The second seal portion 46 prevents the coolant from leaking from the second sub-communicating port 17 b into the radial clearance between the circumferential wall 15 and the outer circumferential portion 39 while the second sub-communicating port 17 b and the second sub-opening portion 41 b are in communication. The second seal portion 46 includes a rotor seal 46 a, an O-ring 46 b, and a coil spring 46 c. The rotor seal 46 a has a cylindrical shape and is inserted in the second sub-communicating port 17 b. The rotor seal 46 a has a radial inner end which is in contact with the outer circumferential portion 39. The O-ring 46 b seals a gap between an inner circumferential surface of the second sub-communicating port 17 b and an outer circumferential surface of the rotor seal 46 a. The coil spring 46 c is radially interposed between the rotor seal 46 a and the second outlet 20 b in a compressed position to bias the rotor seal 46 a in the radially inward direction. The third seal portion 47 is provided to the third sub-communicating port 17 c. The third seal portion 47 prevents the coolant from leaking from the third sub-communicating port 17 c into the radial clearance between the circumferential wall 15 and the outer circumferential portion 39 while the third sub-communicating port 17 c and the third sub-opening portion 41 c are in communication. The third seal portion 47 includes a rotor seal 47 a, an O-ring 47 b, and a coil spring 47 c. The rotor seal 47 a has a cylindrical shape and is inserted in the third sub-communicating port 17 c. The rotor seal 47 a has a radial inner end which is in contact with the outer circumferential portion 39. The O-ring 47 b seals a gap between an inner circumferential surface of the third sub-communicating port 17 c and an outer circumferential surface of the rotor seal 47 a. The coil spring 47 c is radially interposed between the rotor seal 47 a and the third outlet 20 c in a compressed position to bias the rotor seal 47 a in the radially inward direction.

The following description will explain the operation and advantageous effects of the MCV 9 of the Embodiment 1.

The MCV 9 of the Embodiment 1 is so configured that the extending portion 42 is protruding into the space inside the rotor 12. The coolant flowing from the main opening portion 40 toward the x-axis negative direction side therefore collides with the extending portion 42. This causes stagnation of the coolant and might incur a pressure loss of the coolant. If the first sub-opening portion 41 a and the second sub-opening portion 41 b are provided further on the x-axis positive direction side than the extending portion 42, the pressure loss of the coolant can be reduced. On the other hand, this increases an x-axis dimension of the rotor 12, resulting in an increase in size of the MCV 9.

For a solution to the above issue, the rotor 12 of the Embodiment 1 includes the first guide portion 43 on the outer circumferential side of the extending portion 42, which has the radial outer shape which increases from the x-axis positive direction side toward the x-axis negative direction side. This causes the coolant to flow in the radially outward direction along the shape of the first guide portion 43, allowing the coolant to smoothly flow from the main opening portion 40 to the first sub-opening portion 41 a and the second sub-opening portion 41 b. Furthermore, the coolant is prevented from colliding with the extending portion 42, which further prevents the stagnation of the coolant in the vicinity of the extending portion 42. This reduces the pressure loss of the MCV 9. There is no need to increase the x-axis dimension of the rotor 12, which prevents the increase in size of the MCV 9.

The extending portion 42 includes the cylindrical portion 42 b extending from the first guide portion 43 toward the x-axis negative direction side. This allows a portion of the bearing portion 18 to be accommodated in the cylindrical portion 42 b and thus makes the bearing portion 18 overlap with the cylindrical portion 42 b in the x-axis direction. The MCV 9 can be accordingly shortened in x-axis dimension.

The extending portion 42 includes the second guide portion 42 c which connects the cylindrical portion 42 b and the outer circumference of the bottom portion 38. The second guide portion 42 c has a radial outer diameter which increases from the x-axis positive direction side toward the x-axis negative direction side. The second guide portion 42 c is connected to the opening rim on the x-axis negative direction side of the second sub-opening portion 41 b. This causes the coolant to flow from the main opening portion 40 toward the second sub-opening portion 41 b along the shape of the second guide portion 42 c, allowing the coolant to more smoothly flow from the main opening portion 40 to the second sub-opening portion 41 b. The pressure loss therefore can be further reduced.

The rotor 12 includes the connecting portions 38 a and 38 b which extend in the x-axis direction and connect the bottom portion 38 and the second guide portion 42 c. This makes it possible to regulate the rotation angle range of the rotor 12 to fall into the predetermined rotation angle range by using the stopper 14 a which is located on the housing 10 side.

The first sub-opening portion 41 a overlaps with the first guide portion 43 in the x-axis direction. This allows the coolant to more smoothly flow from the main opening portion 40 to the first sub-opening portion 41 a. The pressure loss therefore can be further reduced.

The MCV 9 includes the seal portions 45, 46 and 47 which prevent the coolant from leaking from the sub-opening portions 41 a, 41 b and 41 c into the radial clearance between the housing 10 and the outer circumferential portion 39. This prevents an internal leak of the MCV 9 and restrains a decrease in flow rate of the coolant.

The third sub-opening portion 41 c is provided further on the x-axis positive direction side than the first sub-opening portion 41 a and is larger in opening area than the first and second sub-opening portions 41 a and 41 b. Being the closest to the main opening portion 40 and the largest in opening area among the sub-opening portions 41 a, 41 b and 41 c, the third sub-opening portion 41 a allows the largest amount of coolant to pass therethrough among the sub-opening portions 41 a, 41 b and 41 c. The third sub-communicating port 17 c of the third sub-opening portion 41 a is therefore suitable for connection to the radiator 3 which requires the largest amount of coolant among the heat exchangers 3, 4 and 5 installed in the vehicle.

The first sub-opening portion 41 a includes the summer-use opening portion 41 a 1 and the winter-use opening portion 41 a 2. This makes it possible to achieve the control on flow rate of the coolant in accordance with ambient temperature. The third sub-opening portion 41 c also provides similar advantageous effects.

The bearing portion 18 includes the radial thrust bearing 24 which rotatably supports the drive shaft 13. The circumferential wall 15 includes the slide bearing 44 which is provided at the x-axis positive direction end of the circumferential wall 15 and rotatably supports the x-axis positive direction end of the outer circumferential portion 39. In other words, the rotor 12 is provided, at both x-axial ends thereof, with radial bearings which receive a force coming from the radial (radiation) direction. This makes it possible to stably support the rotor 12 and facilitate the rotation of the rotor 12.

The housing 10 includes the relief hole 28 which extends from the bearing portion 18 in a vehicle upward direction (x-axis negative direction) to be connected to the housing 10. The relief hole 28 is inclined with respect to the x-axis. This enables the air which has entered the bearing portion 18 to be discharged out of the housing 10. The inclination of the relief hole 28 with respect to the x-axis eliminates the necessity of increasing the x-axis dimension of the housing 10.

The bearing portion 18 includes the thrust bearing 27 which supports the drive shaft 13. The rotor 12 receives the force on the x-axis negative direction side thereof from the coolant introduced to the main opening portion 40. The rotor 12 is supported by the thrust bearing 27, which makes it possible to support an x-axis (thrust) force acting on the rotor 12.

The outer circumferential portion 39 is tapered in such a way that the inner diameter increases from the x-axis negative direction side toward the x-axis positive direction side. This makes it easy to remove the insert-molded rotor 12 from a resin mold, facilitating a manufacturing process of the rotor 12.

The outer circumferential portion 39 includes a flange portion 39 a at the x-axis positive direction end thereof. This prevents the coolant from leaking into the radial clearance between the inner circumferential surface of the circumferential wall 15 and the outer circumferential surface of the outer circumferential portion 39 at the x-axis positive direction end of the outer circumferential portion 39. This prevents the internal leak of the MCV 9 and restrains a decrease in flow rate of the coolant.

The cooling system 1 of the Embodiment 1 includes the plurality of heat exchangers 3, 4 and 5, the circuit 7 which cools the engine 2 by circulating the coolant which has passed through the heat exchanges 3, 4 and 5 to be cooled down by the heat exchanges 3, 4 and 5, and the MCV 9 which controls the flow rate of the coolant circulating in the circuit 7. It is then possible to downsize the cooling system 1 and reduce the pressure loss.

The MCV 9 controls the flow rate of the coolant which flows from the engine 2 toward the heat exchangers 3, 4 and 5. The main communicating port 16 is connected to the engine 2 side. The sub-communicating ports 17 a, 17 b and 17 c are connected to the heat exchangers 3, 4 and 5. It is therefore possible to restrain the pressure loss of the coolant which flows from the engine 2 toward the heat exchangers 3, 4 and 5.

Embodiment 2

FIG. 11 is a sectional view taken along line S5-S5 of FIG. 4 according to an Embodiment 2 as viewed from the direction indicated by the arrow.

An MCV 90 of the Embodiment 2 differs from the MCV 9 of the Embodiment 1 in the shape of a second guide portion 42 c. The Embodiment 2 includes a single first sub-opening portion 41 a and a single third sub-opening portion 41 c. According to the Embodiment 2, a bearing portion 18 and a cylindrical portion 42 b do not overlap with each other in the x-axis direction. The second guide portion 42 c of the Embodiment 2 includes not only a second guide portion 42 c 2 corresponding to a second sub-opening portion, which is connected to an opening rim on an x-axis negative direction side of a second sub-opening portion 41 b shown in FIG. 7, but also a second guide portion 42 c 1 corresponding to a first sub-opening portion, which is connected to an opening rim on an x-axis negative direction side of the first sub-opening portion 41 a, and a second guide portion 42 c 3 corresponding to a third sub-opening portion, which is connected to an opening rim on an x-axis negative direction side of the third sub-opening portion 41 c. The second guide portion 42 c 1 corresponding to the first sub-opening portion connects the cylindrical portion 42 b and an outer circumferential portion 39. The second guide portion 42 c 1 corresponding to the first sub-opening portion is tapered in such a way that a radial outer diameter increases from an x-axis positive direction side toward an x-axis negative direction side. The second guide portion 42 c 3 corresponding to the third sub-opening portion connects a tip portion 42 a and the outer circumferential portion 39. The second guide portion 42 c 3 corresponding to the third sub-opening portion is tapered in such a way that a radial outer diameter increases from an x-axis positive direction side toward an x-axis negative direction side. The Embodiment 2 is otherwise similar in configuration to the Embodiment 1, and further descriptions of the configuration of the Embodiment 2 will be omitted.

The MCV 90 of the Embodiment 2 includes the second guide portion 42 c 1 corresponding to the first sub-opening portion, which is connected to the opening rim on the x-axis negative direction side of the first sub-opening portion 41 a. This causes the coolant to flow from a main opening portion 40 toward the first sub-opening portion 41 a along a shape of the second guide portion 42 c 1 corresponding to the first sub-opening portion, allowing the coolant to more smoothly flow from the main opening portion 40 to the first sub-opening portion 41 a. The pressure loss therefore can be further reduced. The second guide portion 42 c 3 corresponding to the third sub-opening portion also provides similar advantageous effects.

Embodiment 3

FIG. 12 is a sectional view taken along line S5-S5 of FIG. 4 according to an Embodiment 3 as viewed from the direction indicated by the arrow.

An MCV 91 of the Embodiment 3 differs from the MCV 90 of the Embodiment 2 in shapes of outlets 20 a, 20 b and 20 c connected to sub-communicating ports 17 a, 17 b and 17 c. End portions of the outlets 20 a, 20 b and 20 c, which are located on the sub-communicating ports 17 a, 17 b and 17 c side (radially inward side), each have an inner diameter which is tapered in such a way that opening area gradually increases from a radially inward side toward a radially outward side. Each of the sub-communicating ports 17 a, 17 b and 17 c is also tapered in such a way that opening area gradually increases from the radially inward side toward the radially outward side. The Embodiment 3 is otherwise similar in configuration to the Embodiment 2, and further descriptions of the configuration of the Embodiment 3 will be omitted.

The MCV 91 of the Embodiment 3 makes it possible to reduce the pressure loss of the coolant since the sub-communicating ports 17 a, 17 b and 17 c are connected to the outlets 20 a, 20 b and 20 c whose opening area increases from the radially inward side toward the radially outward side.

Embodiment 4

FIG. 13 is a schematic view of a cooling system 100 according to an Embodiment 4.

In the cooling system 100 of the Embodiment 4, an MCV 9 adjusts a flow rate of coolant which is fed from heat exchangers 3, 4 and 5 to a water pump 6. The MCV 9 includes a main communicating port 16 which connects a valve element housing portion 19 and a water passage extending toward the water pump 6. A first outlet 20 a connects a water passage, which extends from the heater 5, and a first sub-communicating port 17 a. A second outlet 20 b connects a water passage, which extends from the transmission fluid warmer 4, and a second sub-communicating port 17 b. A third outlet 20 c connects a water passage, which extends from the radiator 3, and a third sub-communicating port 17 c. The Embodiment 4 is otherwise similar in configuration to the Embodiment 1, and further descriptions of the configuration of the Embodiment 4 will be omitted.

The cooling system 100 of the Embodiment 4 is so configured that the MCV 9 controls the flow rate of the coolant which flows from the heat exchangers 3, 4 and 5 toward an engine 2 (intake side of the water pump 6), that a main communicating port 16 is connected to the engine 2, and that the sub-communicating ports 17 a, 17 b and 17 c are connected to the heat exchangers 3, 4 and 5. It is then possible to restrain a pressure loss of the coolant which flows from the heat exchangers 3, 4 and 5 toward the engine 2.

Other Embodiments

The embodiments for carrying out the invention have been explained. The specific configuration of the invention is not limited to those of the embodiments, and all design modifications and the like made without deviating from the gist of the invention are intended to be included in the invention.

The heat source of the cooling system does not have to be an engine and may be an internal combustion engine, a fuel cell or other like heat sources.

The radial thrust bearing of the bearing portion may be a radial bearing.

The number of the sub-communicating ports and of the sub-opening portions may be two, four or more.

Technical ideas which can be understood from the foregoing embodiments are as follows.

According to one aspect, a flow control valve comprises a drive shaft; a housing including a base portion through which the drive shaft extends, a circumferential wall extending from an outer circumference of the base portion toward one axial side of an axial direction, when a direction along an axis of the drive shaft is defined as the axial direction, a valve element housing portion being provided on an inner circumferential side, a main communicating port provided in an end portion on the one axial side of the circumferential wall and communicating with the valve element housing portion, a plurality of sub-communicating ports formed in the circumferential wall and communicating with the valve element housing portion, and a bearing portion formed to protrude from the base portion toward the one axial side and configured to rotatably support the drive shaft; a drive mechanism provided in the other axial side of the base portion and configured to rotationally drive the drive shaft; and a valve element accommodated in the valve element housing portion, the valve element including a bottom portion, an outer circumferential portion which extends from an outer circumference of the bottom portion toward the one axial side, a main opening portion provided in an end portion on the one axial side of the outer circumferential portion and communicating with the main communicating port, a plurality of sub-opening portions formed in the outer circumferential portion and communicating with the respective sub-communicating ports when the valve element is positioned within a predetermined rotation angle range, an extending portion which extends from the bottom portion or the outer circumferential portion toward the one axial side and is fixed to an end portion on the one side of the drive shaft, and a first guide portion provided on an outer circumferential side of the extending portion and having a radial outer shape which increase from the one axial side toward the other axial side, when a direction radial to the axis is defined as a radial direction.

A further preferable aspect according to the above-described aspect is so configured that the extending portion includes a tubular portion which extends from the first guide portion toward the other axial side.

Another preferable aspect according to any one of the above-described aspects is so configured that the extending portion includes a second guide portion which connects the cylindrical portion and the outer circumference of the bottom portion or the outer circumferential portion, the second guide portion having a radial outer shape which increases from the one axial side toward the other axial side.

Still another preferable aspect according to any one of the above-described aspects is so configured that the valve element includes a connecting portion extending in the axis direction and connecting the bottom portion and the second guide portion.

Still another preferable aspect according to any one of the above-described aspects is so configured that at least one of the plurality of sub-opening portions overlaps with the first guide portion in the axis direction.

Still another preferable aspect according to any one of the above-described aspects includes a seal portion configured to prevent fluid from leaking from one of a pair of one of the plurality of sub-communicating ports and a corresponding one of the plurality of sub-opening portions into a radial clearance between the housing and the outer circumferential portion.

Still another preferable aspect according to any one of the above-described aspects is so configured that the plurality of sub-communicating ports include a first sub-communicating port and a second sub-communicating port provided further on the other axial side than the first sub-communicating port, and that the plurality of sub-opening portions include a first sub-opening portion corresponding to the first sub-communicating port and overlapping with the first guide portion in the axis direction, and a second sub-opening portion corresponding to the second sub-communicating port.

Still another preferable aspect according to any one of the above-described aspects is so configured that the valve element includes a second guide portion connected to an opening rim on the other axial side of the second sub-opening portion, the second guide portion having a radial outer shape which increases from the one axial side toward the other axial side.

Still another preferable aspect according to any one of the above-described aspects is so configured that the plurality of sub-communicating ports include a third sub-communicating port provided further on the one axial side than the first sub-communicating port, and that the plurality of sub-opening portions include a third sub-opening portion corresponding to the third sub-communicating port and being larger in opening area than the first sub-opening portion.

Still another preferable aspect according to any one of the above-described aspects is so configured that at least either the first sub-communicating port or the second sub-communicating port comprises two or more first or second sub-communicating ports.

Still another preferable aspect according to any one of the above-described aspects is so configured that the bearing portion includes a first radial bearing which rotatably supports the drive shaft, and that the circumferential wall includes a second radial bearing which is provided in an end portion on the one axial side and rotatably supports the end portion on the one axial side of the outer circumferential portion.

Still another preferable aspect according to any one of the above-described aspects is so configured that the housing includes a relief hole which connects a bearing portion and an exterior portion of the housing and is inclined with respect to the axis.

Still another preferable aspect according to any one of the above-described aspects is so configured that the bearing portion includes a thrust bearing which supports the drive shaft.

Still another preferable aspect according to any one of the above-described aspects is so configured that at least one of the plurality of sub-communicating ports is connected to a conduit and the opening area of the conduct increases from a radially inward side toward a radially outward side.

Still another preferable aspect according to any one of the above-described aspects is so configured that the outer circumferential portion has an inner diameter which increases from the other axial side toward the one axial side.

Still another preferable aspect according to any one of the above-described aspects is so configured that the outer circumferential portion includes a flange portion in an end portion on the one axial side.

From another perspective, a flow control valve comprises a drive shaft; a housing including a valve element housing portion provided in one axial side of an axial direction of the drive shaft, when a direction along an axis of the drive shaft is defined as the axial direction, a main communicating port provided in the one axial side of the valve element housing portion and communicating with the valve element housing portion, and a plurality of sub-communicating ports communicating with the valve element housing portion from a radial direction, when a direction radial to the axis is defined as the radial direction; a drive mechanism provided in the other axial side of the drive shaft and configured to rotationally drive the drive shaft; and a valve element accommodated in the valve element housing portion, the valve element including a bottom portion, an outer circumferential portion extending from an outer circumference of the bottom portion toward the one axial side, a shaft support portion provided further on the one axial side than the bottom portion and configured to receive torque of the drive shaft, a main opening portion provided in an end portion on the one axial side of the outer circumferential portion and communicating with the main communicating port, a plurality of sub-opening portions formed in the outer circumferential portion and overlapping in a radial direction with the respective plurality of sub-communicating ports when the valve element is positioned within a predetermined rotation angle range, when a direction radial to the axis is defined as the radial direction; and a guide portion extending from an outer circumference of the bottom portion or the outer circumferential portion toward the one axial side and toward the radially inward side to be connected to the shaft support portion.

From still another perspective, a cooling system comprises a plurality of heat exchangers configured to cool fluid which has flown into the plurality of heat exchangers; a circuit configured to cool a heat source by circulating the fluid which has passed through the plurality of heat exchangers to be cooled down by the heat exchangers; and a flow control valve configured to control a flow rate of the fluid circulated in the circuit, the flow control valve comprising a drive shaft; a housing including a base portion through which the drive shaft extends, a circumferential wall extending from an outer circumference of the base portion toward one axial side of an axial direction, when a direction along an axis of the drive shaft is defined as the axial direction, a valve element housing portion being provided on an inner circumferential side of the circumferential wall, a main communicating port provided in an end portion on the one axial side of the circumferential wall and communicating with the valve element housing portion, a plurality of sub-communicating ports formed in the circumferential wall and communicating with the valve element housing portion, and a bearing portion formed to protrude from the base portion toward the one axial side and configured to rotatably support the drive shaft; a drive mechanism provided in the other axial side of the base portion and configured to rotationally drive the drive shaft; and a valve element accommodated in the valve element housing portion, the valve element including a bottom portion, an outer circumferential portion extending from an outer circumference of the bottom portion toward the one axial side, a main opening portion provided in an end portion on the one axial side of the outer circumferential portion and communicating with the main communicating port, a plurality of sub-opening portions formed in the outer circumferential portion and configured to come into communication with the respective plurality of sub-communicating ports when the valve element is positioned within a predetermined rotation angle range, an extending portion which extends from the bottom portion or the outer circumferential portion toward the one axial side and is fixed to an end portion on the one side of the drive shaft, and a first guide portion provided on an outer circumferential side of the extending portion and having a radial outer shape which increases from the one axial side toward the other axial side, when a direction radial to the axis is a radial direction.

Preferably, according to the above-described aspect, the flow control valve controls the flow rate of the fluid which flows from the heat source toward the plurality of heat exchangers; the main communicating port is connected to the heat source side; and the plurality of sub-communicating ports are connected to the plurality of heat exchangers side.

Another preferable aspect according to any one of the above-described aspects is configured that the flow control valve controls the flow rate of the fluid which flows from the plurality of heat exchangers toward the heat source, that the main communicating port is connected to the heat source side, and that the plurality of sub-communicating ports are connected to the plurality of heat exchangers side.

The invention is not limited to the embodiments and includes various modifications. For example, the embodiments have been explained in details for ease of understanding of the invention, and the invention does not necessarily have to include all the configurations discussed above. A part of the configuration of any one of the embodiments may be replaced with the configuration of another embodiment. The configuration of any one of the embodiments may be incorporated into the configuration of another embodiment. It is also possible to incorporate or replace a part of the configuration of any one Of the embodiments into or with the configuration of another embodiment, or eliminate a part of the configuration of any one of the embodiments.

The present application claims priority under Japanese Patent Application No. 2016-183645 filed on Sep. 21, 2016. The entire disclosure of Japanese Patent Application No. 2016-183645 filed on Sep. 21, 2016, including the description, claims, drawings and abstract, is incorporated herein by reference in its entirety.

REFERENCE SIGN LIST

-   1: Cooling system -   2: Engine (heat source) -   3: Radiator (heat exchanger) -   4: Transmission fluid warmer (heat exchanger) -   5: Heater (heat exchanger) -   7: Circuit -   9: Mechanical control valve (flow control valve) -   10: Housing -   11: Drive mechanism -   12: Rotor (valve element) -   13: Drive shaft -   14: Base portion -   15: Circumferential wall -   16: Main communicating port -   17: Sub-communicating port -   17 a: First sub-communicating port -   17 b: Second sub-communicating port -   17 c: Third sub-communicating port -   18: Bearing portion -   19: Valve element housing portion -   20 a: First outlet (conduit) -   20 b: Second outlet (conduit) -   20 c: Third outlet (conduit) -   24: Radial thrust hearing (first radial bearing) -   27: Thrust bearing -   28: Relief hole -   38: Bottom portion -   38 a: Connecting portion -   38 b: Connecting portion -   39: Outer circumferential portion -   39 a: Flange portion -   40: Main opening portion -   41: Sub-opening portion -   41 a: First sub-opening portion -   41 b: Second sub-opening portion -   41 c: Third sub-opening portion -   42: Extending portion -   42 b: Cylindrical portion (tubular portion) -   42 c: Second guide portion -   43: First guide portion -   44: Slide bearing (second radial bearing) -   45: First seal portion (seal portion) -   46: Second seal portion (seal portion) -   47: Third seal portion (seal portion) -   100: Cooling system 

1.-20. (canceled)
 21. A valve apparatus comprising: a valve element including a bottom portion, a housing including a valve element housing portion configured to house therein the valve element, a first communication port that communicates between the valve element housing portion and an outside of the valve apparatus, the first communication port facing to the bottom portion, and a second communication port that communicates between the valve element housing portion and an outside of the valve apparatus, the second communication port being provided on a surface of the housing that is different from the first communication port is provided, wherein the communication condition between the first communication port and the second communication port can be changed by rotation of the valve element, and wherein the bottom portion includes an inclined portion that is inclined in the direction away from the first communication port toward an outer periphery side of the bottom portion from the center of the bottom portion, and a restrictive portion being configured to restrict the rotation of the valve element, the restrictive portion provided on a back surface of the bottom portion. 